電磁爐爐盤運輸傳送帶裝置的設(shè)計含9張CAD圖,電磁爐,盤運,傳送帶,裝置,設(shè)計,CAD 附錄A 帶式輸送機技術(shù)的最新發(fā)展 M. A. AlspaughOverland Conveyor Co., Inc. MINExpo 2004拉斯維加斯, 內(nèi)華達州，美國 ，9，27, 2004 摘要 粒狀材料運輸要求帶式輸送機具有更遠的輸送距離、更復雜的輸送路線和更大的輸送量。為了適應社會的發(fā)展，輸送機需要在系統(tǒng)設(shè)計、系統(tǒng)分析、數(shù)值仿真領(lǐng)域向更高層次發(fā)展。傳統(tǒng)水平曲線和現(xiàn)代中間驅(qū)動的應用改變和擴大了帶式輸送機發(fā)展的可能性。本文回顧了為保證輸送機的可靠性和可用性而運用數(shù)字工具的一些復雜帶式輸送機。 前言 雖然這篇文章的標題表明在皮帶輸送機技術(shù)中將提出“新”發(fā)展，但是提到的大多思想和方法都已存在很長時間了。 我們不懷疑被提出一些部件或想法將是“新”的對你們大部分人來說。所謂的“新”就是利用成熟的技術(shù)和部件組成特別的、復雜的系統(tǒng)； “新”就是利用系統(tǒng)設(shè)計工具和方法，匯集一些部件組成獨特的輸送機系統(tǒng)，并解決大量粒狀原料的裝卸問題；“新”就是在第一次系統(tǒng)試驗(委任)之前利用日益成熟的計算機技術(shù)進行準確節(jié)能計算機模擬。 同樣，本文的重點是特定復雜系統(tǒng)設(shè)計及滿足長距離輸送的要求。 這四個具體課題將覆蓋： l 托輥阻力 l 節(jié)能 l 動力分散 l 分析與仿真 節(jié)能 減小設(shè)備整體電力消費是所有項目的一個重要方面，皮帶輸送機是也不例外。 雖然與其他運輸方法比較皮帶輸送機總是運輸大噸位高效率的手段，但是減少帶式輸送機的功率消耗的方法還是很多的。 皮帶輸送機的主要阻力組成部分有： l 托輥阻力 l 托輥與皮帶的摩擦力 l 材料或輸送帶彎曲下垂引起的阻力 l 重力 這些阻力加上一些混雜阻力組成輸送材料所需的力。1 在一臺輸送長度400米的典型短距離輸送機中,力可以分為如圖1所示的幾個部分，圖中可以看出提升力所占比例最大，而阻力還是占絕大部分。 圖1 在高傾斜輸送帶中如礦用露天傾斜輸送帶，所受力可分解為圖2所示的幾個部分，其中提升力仍占巨大比例。由于重力是無法避免的，因此沒有好的方法減少傾斜式輸送機所受力。 圖 2 但是在長距離陸上輸送機中，所受力更趨向圖3所示的幾個部分，不難看出摩擦力幾乎是所受力的全部。這種情況下考慮主要受力才是最重要的。 圖 3 力量演算具體是超出本文的范圍之外，但是值得一提的是，在過去幾年對所有四個區(qū)域橡膠凹進、對準線和材料或者傳送帶彎曲等方面的重要研究都在進行。 并且，雖然在處理每特定區(qū)域時大家有不同意見，通常對整體項目經(jīng)濟是必要和重要的是被大家被接受的。 在2004個SME年會上，MAN Takraf的Walter Kung介紹了題為“Henderson粗糙礦石輸送系統(tǒng)—回顧組裝、起動和操作”2。 這個項目在1999年12月被實施并且包括一個24公里(3飛行)陸上轉(zhuǎn)達的系統(tǒng)替換地下礦碾碎路軌貨車使用系統(tǒng)。 圖4 - Henderson PC2到PC3調(diào)動站 最長的傳動機在這個系統(tǒng)(PC2)是16.28公里長與475m升距。最重要的系統(tǒng)事實是提供的功率(4000千瓦在1783 mtph 和4.6 m/s)的50% 被要求用來轉(zhuǎn)動一條空載的帶子，因此輸送系統(tǒng)的效率是很重要的。需密切注意托輥、傳送帶蓋子橡膠和對準線。用文件說明有關(guān)的效率的差別是的一種方法， 使用"相等的摩擦系數(shù)f"的22101標準定義作為比較主要抵抗的總數(shù)的另一種方法。過去，象這樣典型輸送裝置的綜合設(shè)計噪音系數(shù)大約是0.016f。MAN Takraf正估計他們對力的敏感達到到0.011的f，超過30%的削減。這在減少設(shè)備建造成本上做出了重大貢獻。通過六次的實際動態(tài)測量顯示價值是0.0075，甚至比期望值低30%。 Kung先生強調(diào)這將在僅僅用電費用一項上每年減少費用10萬美元。 線路優(yōu)化 圖5 – 中國天津 水平適應性 當然最高效率的材料運輸方式是從一點到下一點的直線輸送。 但是，由于自然和認為障礙的存在，我們在長距離輸送過程中直接直線輸送的可能性越來越小。第一臺水平彎曲輸送機已在很多年前安裝使用，但它今天似乎關(guān)于安裝的每臺陸上傳動機在方向至少有一個水平變化。并且今天的技術(shù)允許設(shè)計師相對地容易地調(diào)整這些曲線。 圖5和圖6顯示的是把煤從蘊藏地運輸?shù)街袊旖蚋劭诠芾硖幍年懮陷斔脱b置。這套運輸機由E.J. O’Donovan & Associates設(shè)計，由 Continental Conveyor Ltd of Australia 公司承建，長達9千米的輸送距離4臺1500千萬電機驅(qū)動運輸能力達6000 mtph 。 圖6 – 天津輸送線平面圖 Wyodak礦位于美國懷俄明州粉河流域，是記錄中最古老的連續(xù)經(jīng)營的煤礦，自1923年運營至今。它一般運用坡面(圖7)從新的礦坑到裝置756m (2,482 ft)與700m (2,300 ft)水平的半徑。 這表明由于水平輪的應用輸送機不需要設(shè)計太長3。 圖7- Wyodak 煤礦 隧道式 如通過沒有水平曲線線路，另一項產(chǎn)業(yè)，隧道挖掘，就不能使用帶式輸送機了。 隧道就想象廢水和運輸那樣的基礎(chǔ)設(shè)施在全世界有。 移動隧道糞肥的最有效率的方法通過把推進的輸送裝置和隧道機器的后部連結(jié)起來。但是這些隧道極少是直的。 這里有一個例子，西班牙10.9m直徑隧道的在巴塞羅那之下作為地鐵(火車)引伸項目一部分。大陸輸送機機有限公司安裝了前4.7km傳動機如圖8和9所顯示和最近接受合同安裝第二臺8.39公里輸送機。 圖 8- 巴塞羅那隧道平面圖 圖 9- 隧道內(nèi)部 另一個例子， 肯珀建設(shè)邊境時，建設(shè)一個直徑3.6米長6.18公里的隧道作為大都市圣路易斯的下水道區(qū)。鮑姆加特納隧道(圖10)將裝有600毫米寬的用4個中間運動用帶子系住的6.1 公里輸送裝置。 圖10- 鮑姆加特納隧道平面圖 管狀輸送裝置 如果常規(guī)輸送機不能滿足必須的輸送要求，帶式輸送機的一種管狀輸送機會是不錯的選擇。 圖 11- 管狀輸送裝置 它最簡單的描述，管狀輸送機就是由管狀橡膠管和空轉(zhuǎn)輥組成。這種設(shè)計具有其他傳送方式的優(yōu)點，更有自己的特點。 托輥可以在各個方向傳力允許更復雜的曲線輸送。這些曲線可以是水平或垂直或混合形式。這樣的輸送機輸送帶與托輥之間的重力和摩擦力保證原料在輸送管道內(nèi)。 Figure 12 管狀輸送機的另一個好處可以輸送粉狀原料并且可以減少溢出浪費，因為材料是在管道內(nèi)部。一個典型的例子是環(huán)境效益和適應性特好的美國猶他州地平線礦（圖12）。這個長3.38公里的管狀輸送機由ThyssenKrupp Robins 安裝通過一個國家森林并且橫斷了22個水平段和45個垂直段。 Metso 繩索輸送機 另一種由常規(guī)衍變來的是Mesto 繩索輸送機（MRC），通常以纜繩傳送帶著名。這個產(chǎn)品以長途輸送著名，在距澳大利亞30.4公里的沃斯利鋁土礦上應用的輸送帶是最長的單個飛行輸送機。在鋼繩輸送機上，驅(qū)動裝置和運載媒介是分離的。 圖13 - MRC-平直的部分 這種驅(qū)動與輸送裝置的分離允許輸送有小半徑的水平彎曲，這種設(shè)計優(yōu)于根 距張緊力和地勢的傳統(tǒng)設(shè)計。 圖 14 MRC與常規(guī)輸送機水平曲線的不同 圖 15- 位于加拿大 Line Creek的MRC 圖15顯示的是位于加拿大Line Creek河畔的一條長10.4公里水平半徑430米的纜繩輸送帶 立式輸送裝置 有時材料需要被提升或下降而常規(guī)輸送機被限制在16—18度附近的傾斜角度內(nèi)。但是帶式輸送機的非傳統(tǒng)衍變不管是在增加角度還是平直方面都是相當成功的。 大角度輸送機 第一臺大角度輸送機由Continental Conveyor & Equipment Co.公司生產(chǎn)，非常利用常規(guī)輸送機零部件（圖16）構(gòu)成。當原料在兩條帶子之間輸送時，被稱為三明治輸送裝置。 圖16 Continental 公司的第100套大傾角輸送裝置采用獨特的可平移式設(shè)計，作為Mexican de Canenea的堆過濾墊（圖17）。 Figure 17 垂直式輸送裝置 第二種立式輸送裝置展現(xiàn)的是一種非常規(guī)的帶式裝置，它可以實現(xiàn)垂直輸送（圖18）。 這種Mesto 垂直輸送機，2001年由Frontier Kemper 安裝在白縣煤礦Pattiki 2礦（圖19），將煤由273米深的礦井輸出并達到1,818 mtph的輸送能力。 圖18 圖19- Pattiki 2礦 動力分散 在最近過去的一段時間里，一種最有趣的發(fā)展是電力沿輸送道路的分配?？吹捷斔蜋C驅(qū)動裝置安裝在收尾末端，讓尾端驅(qū)動完成輸送帶的拉緊輸送工作。但是現(xiàn)在的發(fā)展觀念是把驅(qū)動安裝在任何需要的位置。 在帶式輸送機上多個位置安裝動力源的想法已經(jīng)存在很長一段時間了。第一次應用是1974年安裝在美國Kaiser煤礦。緊接著是在地下煤礦中得到應用，而且長臂開采法也越來越體現(xiàn)它的優(yōu)越性。采礦設(shè)備的效率和能力也得到巨大改善。礦工們也開始尋找大的礦區(qū)從而減少移動大型采礦設(shè)備的次數(shù)及時間。礦井寬度和礦井分格長度都得到增加。 當?shù)V井分格長度增加后，輸送問題開始出現(xiàn)。接近4-5千米的輸送長度所需要的電力和輸送帶的強度比以前地下煤礦需要的大很多。問題是大號的高電力驅(qū)動裝置安裝及移動困難。雖然膠帶技術(shù)能夠滿足膠帶所需強度要求，它意味著需要比鋼鐵更重要的強度及加硫處理。由于長臂開采法的盤區(qū)傳動機經(jīng)常推進和后退，礦工需要經(jīng)常增加或取消滾筒的正傳與逆轉(zhuǎn)。而且硫化結(jié)合需要長期維護以保證強度，因而失去的產(chǎn)品生產(chǎn)時間在一個完全盤區(qū)中是很嚴重的?，F(xiàn)在需要超過風險，并且中間驅(qū)動的應用限制了輸送帶的伸長及張緊這樣就允許纖維膠帶在長距離輸送機中應用。 現(xiàn)今，中間驅(qū)動技術(shù)被很好的接受并越來越廣泛的應用于地下煤礦中。世界范圍內(nèi)的許多礦把這項技術(shù)整合到現(xiàn)在和未來礦業(yè)計劃當中來增加他們的整體采礦效率和效益6。 表20所示的張緊圖顯示了中間驅(qū)動的重大好處。這種平面前驅(qū)的輸送機有簡單的皮帶張力分布如黑色線條所示。雖然平均皮帶張力在每個周期期間只約為最大值的40%，但必須圍繞最大估量值附近。黑色線條的急劇回落表示頂頭滑輪要求的總扭矩和力量來啟動輸送機。 將受力分解到兩個地點（紅線），當總功率基本相同的情況下，皮帶張力差不多減少40%。因此更小的輸送帶和更小的電源組可以得到運用。為了進一步擴展這種方式，增加第二中間驅(qū)動（綠線），皮帶峰頂張力進一步下降。 隧道產(chǎn)業(yè)也迅速采用這種技術(shù)并且把這項技術(shù)提高到更好的水平，更復雜更先進。但挖隧道最需要的是水平曲線的進步。 通過中間驅(qū)動（圖21）的一種應用例如Baumgartner 隧道如前圖10所描述，皮帶張緊力可以通過在重要的地點安裝戰(zhàn)略驅(qū)動來控制，從而實現(xiàn)輸送帶的小曲線換向。 圖20 圖21 在圖22中，綠色投影區(qū)域代表彎曲結(jié)構(gòu)的地點。藍色線條代表輸送帶運載面，粉紅色線條代表輸送帶返回面?？梢园l(fā)現(xiàn)在彎曲半徑最小750米時輸送帶運載面和返回面所受張緊力均達到最小。 圖22 盡管到目前為止，這項技術(shù)陸上輸送機中沒有廣泛的應用，一些傾向于水平曲線的技術(shù)卻得到發(fā)展。圖23顯示了南美洲的一條長8.5千米硬巖層輸送帶，它需要4個中間驅(qū)動來實現(xiàn)4段2000米半徑的曲線轉(zhuǎn)向。 Figure 23- 平面圖 圖24顯示在彎曲段有與沒有驅(qū)動時輸送帶的張緊力比較。 分散驅(qū)動的優(yōu)點在MRC纜繩輸送帶中也得到應用。然而張緊運載的繩索有別于負載傳送帶，安裝中間驅(qū)動更加容易，輸送的原料不用離開運載輸送帶的表面。張緊運載的繩索與輸送帶分開足夠的距離，便利在安裝中間驅(qū)動后繼續(xù)工作。(圖25). 圖24- 張緊曲線 圖25 分析與仿真 許多人在爭論我們建造以上描述的復雜輸送機的能力時，歸因于許多分析和仿真工具的發(fā)展。組件制造商可以通過測試他的產(chǎn)品以保證符合規(guī)格；然而系統(tǒng)工程師很少能測試完成的系統(tǒng)，知道它在站點完成。所以計算方法和工具在模仿各種各樣不同學科和組分上的作用是絕對重要的。 動態(tài)開始和停止 當進行開始和停止試驗時，假設(shè)所有的質(zhì)量單元同時加速；也就是把輸送帶看做一個剛體（非彈性體）。實際上，推進扭矩通過滑輪產(chǎn)生的壓力波傳遞給輸送帶，并通過壓力波的傳播帶動輸送帶運行。壓力在輸送帶上傳播時發(fā)生由阻礙輸送帶運行的阻抗產(chǎn)生的縱波引起的變化。7 從1959開始許多出版物都指出彈性輸送帶的大輸送量、長距離輸送機在停止和啟動時會導致傳動裝置、驅(qū)動裝置、張緊裝置的選擇等錯誤。對彈性瞬變響應的疏忽可能導致不精確的后果： l 輸送帶最大壓力 l 滑輪上的最大壓力 l 輸送帶的最小壓力及原料泄漏 l 提升壓力要求 l 提升行程和速度要求 l 驅(qū)動輪 l 啟動轉(zhuǎn)矩 l 制動轉(zhuǎn)矩 l 各驅(qū)動間的負載分擔 l 原料在斜面上的穩(wěn)定性 為了長期應用，通過數(shù)學模型對彈性輸送帶在開始和停止時的狀態(tài)進行模擬是非常重要的。 一部完整輸送機系統(tǒng)的模型可通過劃分輸送機為一系列的有限元素來實現(xiàn)。每個元素由一個質(zhì)量和一個流變彈簧組成，如圖26所示。 圖 26 許多分析輸送帶無力性能的方法都在研究，如把它看做一個流變彈簧，而且大量的技術(shù)也被用來這方面的研究。一個合適的模型需要包含以下幾個方面： 1. 傳送帶縱向拉伸量的彈性模數(shù) 2. 對從屬運動的阻抗 3. 凹陷處的粘彈性損失 4. 由于輸送帶的下垂引起的輸送帶模數(shù)變動 因為純數(shù)學解決這些動態(tài)問題是非常復雜的，它的目標不是詳述基礎(chǔ)的動態(tài)理論分析。相反，它的目的是讓長距離輸送、水平彎曲、分散驅(qū)動在輸送機上更普遍，對傳送帶停止和開始進行彈性動態(tài)分析的重要性是開發(fā)適當?shù)目刂扑惴ā? 以圖23 8.5千米輸送機為例，兩個虛擬開始被模擬來比較它們的控制算法。一種是兩個1000千瓦的驅(qū)動安裝在頭部尾端，二個1000千瓦驅(qū)動安裝在輸送面的中點，另一個1000千瓦驅(qū)動安裝在尾部，要極端小心保證所有驅(qū)動的協(xié)調(diào)與維護。 圖27顯示一個不協(xié)調(diào)并嚴重擺動輸送機120秒啟動的扭矩圖及其相應的速度輸送帶擺動圖。T1/T2滑動比率表明推進滑動可能發(fā)生。圖28顯示對應的一個180秒啟動圖，并能夠安全和順利的加速輸送機。 圖27-120 秒惡劣啟動 圖 28- 180 良好啟動 轉(zhuǎn)運站的質(zhì)流 運用中間驅(qū)動和鏈板輸送能長期使用的一個原因就是消除轉(zhuǎn)運站。許多最困難的問題在帶式輸送機裝貨和卸載附近集中。傳送溜槽通常選在輸送機高效維護區(qū)域，同時重大生產(chǎn)風險在這里集中。 l 堵塞 l 輸送帶和滑道損傷和磨蝕物質(zhì)退化 l 粉塵 l 裝貨/溢出偏心 過去，沒有分析工具，反復試驗和經(jīng)驗是設(shè)計工程師唯一可用的設(shè)計方法；現(xiàn)在，數(shù)值仿真方法的存在允許設(shè)計師在制造之前測試他們的設(shè)計。 數(shù)字仿真是根據(jù)一個實際的物理系統(tǒng)設(shè)計的模型，并在計算機上模擬和分析結(jié)果。仿真體現(xiàn)在實踐中學習的精神。為了了解現(xiàn)實及其復雜性，我們在計算機上建立虛擬物體并動態(tài)的觀察它們間的相互作用。 分離元素法是解決工程學和應用科學如粒狀材料流等不連續(xù)的機械行為問題的一種數(shù)字模擬技術(shù)。值得注意的是，由非連續(xù)行為引起的行為不能依靠傳統(tǒng)基基于計算機的連續(xù)流塑造方法例如有限元素分析、有限差規(guī)程和甚而計算流體動力學(CFD)的來進行模擬。 DEM系統(tǒng)模仿每個部件或微粒的動態(tài)行為和機械互作用，并提供分析期間每個部件和微粒的位置、速度、和力量的詳細描述。8 在分析過程中，微粒被塑造成有形狀的物體，這些物體之間及于界限表面、運載表面互相作用，這些物體接觸和碰撞形成他們之間法向、切向力. 正常接觸分力在碰撞過程中引起一個線性有彈性恢復的組分和一個粘阻力來模擬能量損失。線性有彈性組分系數(shù)根據(jù)自身屬性確定，正常粘滯系數(shù)可以根據(jù)一個等效恢復系數(shù)的彈簧來塑造（圖29）。 圖29 圖30顯示顆粒下落通過傳送帶溜槽。圖示中顆粒的顏色代表他們的速度。紅色代表零速度，而綠色代表最高速度。也許這些工具的最大好處就是一位老練的工程師能通過形象化表示設(shè)計施工前有個行像的表現(xiàn)。有了這個形象的感覺在施工過程中可以盡量減少不必要的工作。 其他定量數(shù)據(jù)也可能被隱藏包括在輸送帶或滑道墻壁的沖擊和剪切力。 圖30 前景 更大的帶式輸送機 本文提到了一臺最長的唯一飛行常規(guī)輸送機，長16.26公里的Henderson PC2。但一臺19.1公里的輸送機在美國正在建設(shè)中，并且一臺23.5公里的飛行式輸送機在澳洲被設(shè)計。其他長30-40公里的輸送機在世界其他地區(qū)討論研究。 當定量凹進的方式為人所知，輸送帶制造商開發(fā)了低輾壓抗壓儲力10-15%的橡膠輸送帶。與改進的設(shè)施方法和對準線一起作用，節(jié)能是可以實現(xiàn)的。 地下煤礦和隧道承包商將繼續(xù)使用已經(jīng)證明對他們有好處的分散驅(qū)動方式；至少有兩種在表面輸送機中安裝中間驅(qū)動的輸送機在2005年運行。 在德國，RWE Rheinbraun 使煤礦用輸送機輸送量達到30,000 tph ，并且其他表面煤礦也在有計劃的接近這個輸送量。隨著輸送兩的增加，輸送帶的速度也在增加，這樣就要求更好的設(shè)備、工藝公差、阻力和動力分析。 我們希望輸送機能夠更遠、更寬、更高、更快，采用所有分析工具來分析系統(tǒng)性能。因為每臺輸送機都是獨特的，我們唯一的預見方式就是外面的數(shù)據(jù)分析和模仿工具。因此由于外面的目標越來越大，我們有必要改進設(shè)計工具。 附錄B Latest Developments in Belt Conveyor Technology M. A. Alspaugh Overland Conveyor Co., Inc. Presented at MINExpo 2004Las Vegas, NV, USA September 27, 2004 Abstract Bulk material transportation requirements have continued to press the belt conveyor industry to carry higher tonnages over longer distances and more diverse routes. In order keep up, significant technology advances have been required in the field of system design, analysis and numerical simulation. The application of traditional components in non-traditional applications requiring horizontal curves and intermediate drives have changed and expanded belt conveyor possibilities. Examples of complex conveying applications along with the numerical tools required to insure reliability and availability will be reviewed. Introduction Although the title of this presentation indicates “new” developments in belt conveyor technology will be presented, most of the ideas and methods offered here have been around for some time. We doubt any single piece of equipment or idea presented will be “new” to many of you. What is “new” are the significant and complex systems being built with mostly mature components. What is also “new” are the system design tools and methods used to put these components together into unique conveyance systems designed to solve ever expanding bulk material handling needs. And what is also “new” is the increasing ability to produce accurate Energy Efficiency computer simulations of system performance prior to the first system test (commissioning). As such, the main focus of this presentation will be the latest developments in complex system design essential to properly engineer and optimize today’s long distance conveyance requirements. The four specific topics covered will be: l Idler Resistance l Energy Efficiency l Distributed Power l Analysis and Simulation Energy Efficiency Minimizing overall power consumption is a critical aspect of any project and belt conveyors are no different. Although belt conveyors have always been an efficient means of transporting large tonnages as compared to other transport methods, there are still various methods to reduce power requirements on overland conveyors. The main resistances of a belt conveyor are made up of: l Idler Resistance l Rubber indentation due to idler support l Material/Belt flexure due to sag being idlers l Alignment These resistances plus miscellaneous secondary resistances and forces to over come gravity (lift) make up the required power to move the material.1 In a typical in-plant conveyor of 400m length, power might be broken into its components as per Figure 1 with lift making up the largest single component but all friction forces making up the majority. Figure 1 In a high incline conveyor such as an underground mine slope belt, power might be broken down as per Figure 2, with lift contributing a huge majority. Since there is no way to reduce gravity forces, there are no means to significantly reduce power on high incline belts. Figure 2 But in a long overland conveyor, power components will look much more like Figure 3, with frictional components making up almost all the power. In this case, attention to the main resistances is essential. Figure 3 The specifics of power calculation is beyond the scope of this paper but it is important to note that significant research has been done on all four areas of idlers, rubber indentation, alignment and material/belt flexure over the last few years. And although not everyone is in agreement as to how to handle each specific area, it is generally well accepted that attention to these main resistances is necessary and important to overall project economics. At the 2004 SME annual meeting, Walter Kung of MAN Takraf presented a paper titled “The Henderson Coarse Ore Conveying System- A Review of Commissioning, Start-up and Operation”2. This project was commissioned in December 1999 and consisted of a 24 km (3 flight) overland conveying system to replace the underground mine to mill rail haulage system. Figure 4- Henderson PC2 to PC3 Transfer House The longest conveyor in this system (PC2) was 16.28 km in length with 475m of lift. The most important system fact was that 50% of the operating power (~4000 kW at 1783 mtph and 4.6 m/s) was required to turn an empty belt therefore power efficiency was critical. Very close attention was focused on the idlers, belt cover rubber and alignment. One way to document relative differences in efficiency is to use the DIN 22101 standard definition of “equivalent friction factor- f” as a way to compare the total of the main resistances. In the past, a typical DIN fused for design of a conveyor like this might be around 0.016. MAN Takraf was estimating their attention to power would allow them to realize an f of 0.011, a reduction of over 30%. This reduction contributed a significant saving in capital cost of the equipment. The actual measured results over 6 operating shifts after commissioning showed the value to be 0.0075, or even 30% lower than expected. Mr. Kung stated this reduction from expected to result in an additional US$100, 000 savings per year in electricity costs alone. Route Optimization Figure 5- Tiangin China Horizontal Adaptability Of course the most efficient way to transport material from one point to the next is as directly as possible. But as we continue to transport longer distances by conveyor, the possibility of conveying in a straight line is less and less likely as many natural and man-made obstacles exist. The first horizontally curved conveyors were installed many years ago, but today it seems just about every overland conveyor being installed has at least one horizontal change in direction. And today’s technology allows designers to accommodate these curves relatively easily. Figures 5 and 6 shows an overland conveyor transporting coal from the stockpile to the shiploader at the Tianjin China Port Authority installed this year. Designed by E.J. O’Donovan & Associates and built by Continental Conveyor Ltd of Australia, this 9 km overland carries 6000 mtph with 4x1500 kW drives installed. Figure 6- Tiangin China Plan View The Wyodak Mine, located in the Powder River Basin of Wyoming, USA, is the oldest continuously operating coal mine in the US having recorded annual production since 1923. It currently utilizes an overland (Figure 7) from the new pit to the plant 756m long (2,482 ft) with a 700m (2,300 ft) horizontal radius. This proves a conveyor does not need to be extremely long to benefit from a horizontal turn. 3 Figure 7- Wyodak Coal Tunneling Another industry that would not be able to use belt conveyors without the ability to negotiate horizontal curves is construction tunneling. Tunnels are being bore around the world for infrastructure such as waste water and transportation. The most efficient method of removing tunnel muck is by connecting an advancing conveyor to the tail of the tunnel boring machine. But these tunnels are seldom if ever straight. One example in Spain is the development of a 10.9m diameter tunnel under Barcelona as part of the Metro (Train) Extension Project. Continental Conveyor Ltd. installed the first 4.7km conveyor as shown in Figures 8 and 9 and has recently received the contract to install the second 8.39 km conveyor. Figure 8- Barcelona Tunnel Plan View Figure 9- Inside Tunnel In another example, Frontier Kemper Construction is currently starting to bore 6.18 km (20,275 ft) of 3.6m (12 foot) diameter tunnel for the Metropolitan St. Louis (Missouri) Sewer District. The Baumgartner tunnel (Figure 10) will be equipped with a 6.1 km conveyor of 600mm wide belting with 4 intermediate drives. Figure 10- Baumgartner Tunnel Plan View Pipe Conveyors And if conventional conveyors cannot negotiate the required radii, other variations of belt conveyor such as the Pipe Conveyor might be used. Figure 11- Pipe Conveyor In its simplest description, a pipe conveyor consists of a rubber conveyor belt rolled into a pipe shape with idler rolls. This fundamental design causes the transported material to be totaled enclosed by the belt which directly creates all the advantages. The idlers constrain the belt on all sides allowing much tighter curves to be negotiated in any direction. The curves can be horizontal, vertical or combinations of both. A conventional conveyor has only gravity and friction between the belt and idlers to keep it within the conveyance path. Figure 12 Another benefit of pipe conveyor is dust and/or spillage can be reduced because the material is completely enclosed. A classic example where both environment and adaptability to path were particularly applicable was at the Skyline Mine in UT, USA (Figure 12). This 3.38 km (11,088 ft) Pipe Conveyor was installed by ThyssenKrupp Robins through a national forest and traversed 22 horizontal and 45 vertical curves.4 Metso Rope Conveyor Another variation from conventional is the Metso Rope Conveyor (MRC) more commonly known as Cable Belt. This product is known for long distance conveying and it claims the longest single flight conveyor in the world at Worsley Alumina in Australia at 30.4 km. With Cable Belt, the driving tensions (ropes) and the carrying medium (belt) are separated (Figure 13). Figure 13- MRC- Straight Section This separation of the tension carrying member allows positive tracking of the ropes (Figure 14) which allow very small radius horizontal curves to be adopted that defeat the traditional design parameters based on tension and topography. Figure 14 MRC vs. Conventional Conveyor in Horizontal Curve Figure 15- MRC at Line Creek, Canada Figure 15 shows a 10.4 km Cable Belt with a 430m horizontal radius at Line Creek in Canada. Vertical Adaptability Sometimes material needs to be raised or lowered and the conventional conveyor is limited to incline angles around 16-18 degrees. But again non-traditional variations of belt conveyors have been quite successful at increased angles as well as straight up. High Angle Conveyor (HAC.) The first example manufactured by Continental Conveyor & Equipment Co. uses conventional conveyor components in a non-conventional way (Figure 16). The concept is known as a sandwich conveyor as the material is carried between two belts. Figure 16 Continental’s 100th installation of the HAC was a unique shiftable installation at Mexican de Canenea’s heap leach pad (Figure 17). Figure 17 Pocketlift. The second example shows a non-traditional belt construction which can be used to convey vertically (Figure 18). This Metso Pocketlift. belt was installed by Frontier Kemper Constructors at the Pattiki 2 Mine of White County Coal in 2001 (Figure 19). It currently lifts 1,818 mtph of run-of-mine coal up 273 m (895 ft). 5 Figure 18 Figure 19- Pattiki 2 Mine Distributed Power One of the most interesting developments in technology in the recent past has been the distribution of power along the conveyor path. Is has not been uncommon to see drives positioned at the head and tail ends of long conveyors and let the tail drive do the work of pulling the belt back along the return run of the conveyor. But now that idea has expanded to allow designers to position drive power wherever it is most needed. The idea of distributing power in multiple locations on a belt conveyor has been around for a long time. The first application in the USA was installed at Kaiser Coal in 1974. It was shortly thereafter that underground coal mining began consolidating and longwall mines began to realize tremendous growth in output. Mining equipment efficiencies and capabilities were improving dramatically. Miners were looking for ways to increase the size of mining blocks in order to decrease the percentage of idle time needed to move the large mining equipment from block to block. Face widths and panel lengths were increasing. When panel lengths were increased, conveyance concerns began to appear. The power and belt strengths needed for these lengths approaching 4 -5 km were much larger than had ever been used underground before. Problems included the large size of high power drives not to mention being able to handle and move them around. And, although belting technology could handle the increased strength requirements, it meant moving to steel reinforced belting that was much heavier and harder to